Ski-Doo E-TEC Turbo System

Overview

FEATURES

66 Series Aerocharger

Tuned Airbox

Stainless Steel Exhaust

Silicone Charge Tube

Snow to Air Intercooler

Stainless Heat Shield

Dome Filter

Fuel Controller

Boost & AFR Guages

Complete Clutching

OVERVIEW

Aerocharger co-developed the Ski-Doo E-TEC turbo system with BRP Racing starting in 2009 for RMSHA, and the Aerocharger was the first working kit available at the E-TECs release in 2011. BRP Racing dyno’d the Aerocharger system and registered 240hp at only 7psi, and this system can be set to produce a range of 200-300hp. This system was designed in close collaboration with BRP Racing, who contributed design criteria and system specifications to ensure that a properly designed aftermarket turbo kit would be available for the E-TEC snowmobiles. The Aerocharger is a substantial innovation over conventional turbocharger technology, making it ideal for use with Rotax 2-stroke engines. The Aerocharger E-TEC system was built to prioritize horsepower-generating efficiency, and this equals an ultra-responsive, ridable system that excels at high altitude and on technical terrain.

We strive to provide the most comprehensive package possible right out of the box, and this season we are improving on it with a few refinements.

Three Aerocharged Ski-Doo E-TECs

WEIGHT REDUCTION: Whether climbing, side hilling or just getting unstuck from the deep stuff, mountain riders understand that every ounce makes a difference. Last year’s Aerocharger system totaled out to an overall sled weight reduction of -2 pounds, making it the lightest kit available industry-wide. For this season, total system weight will be dropped by another -6 pounds as a result of improved component machining.

SLED VENTING. Heat dissipation is critical for best turbo performance, so we went ahead and included turbo side and clutch side Snow Silk vent kits in every Aerocharger snowmobile turbo package this season:

CLUTCHING. Clutch setups have been the most requested item. Getting this right is one of the biggest factors in your turbo sled running the best it can, so now an extensive custom clutch setup is included with every Aerocharger snowmobile turbo system. This includes custom ramps, weights, gearing, and a very cool custom helix with improved angles for turbocharged operation:

ABOUT AEROCHARGER

Aerocharger Turbo Systems is a 3rd generation engineering company and the manufacturer of the Aerocharger, a specialized Variable Vane Turbo. Aerocharger also directly researches and develops turbo kits using the fully optimized Aerocharger for UTV, snowmobile, motorcycle and automotive applications. Aerocharger’s engineers have expert technical backgrounds in fuel management and thermal dynamics, and Aerocharger systems are carefully designed to prioritize efficiency, power and response.

System Specs

Performance Gains

BRP Racing dyno’d the Aerocharger E-TEC 800 system, and registered 240 hp at 7psi boost. The average Aerocharger is set at 7psi boost.

Fueling

For best performance, Aerocharger recommends using a minimum of 100 octane fuel when running this system. Pump gas not be used under 7000 foot elevation. A pump gas option is in development, and more information will be available later in the season season.

This fuel guide lists recommended octane levels based on boost and altitude. This chart is for reference only – many factors affect safe octane such as air density, temperature, and tolerance specific to your motor. This chart is intended to suggest rough guidelines based on the most common operating environments.

Boost Levels

Max boost level is mechanically set by a pre-loaded spring inside the Aerocharger’s integrated boost controller, and aftermarket boost controllers can also be used for additional boost control. See the Aerocharger page for additional information.

An Intercooler is recommended for E-TECs set at boost levels higher than 7psi. Exclusively for the Aerocharger E-TEC System, an innovative new Snow-to-Air Intercooler is available as an option for a consistently cooler air charge. Click the upgrade tab to read more about the Snow-to-Air Intercooler.

Big Bore/Compression Mods

The Aerocharger E-TEC System is compatible with engine mods such as big bore kits or lower/higher compression.

Reliability & Support

Aerocharger has a well-tested, strong-running and reliable turbo system. The Aerocharger doesn’t require any more care or maintenance than any other turbocharger, and when properly installed your Aerocharger system should outlast the life of your sled. We will make sure you have the support you need – for any questions, troubleshooting or maintenance, don’t hesitate to directly contact Aerocharger’s engineers or your nearest Aerocharger dealer.

Installation

Aerocharger systems are designed so they can be installed at home by a rider with moderate mechanical ability and common garage tools, but many Aerocharger customers prefer to have their turbo system installed at a dealership or performance shop. Dealers report prefering Aerocharger technology because Aerocharger systems are properly designed and either simplify or eliminate many fail-prone components, thereby requiring much less support and maintenance.

Non-Flooded Bearings

Welded Turbine Inlet

Aerochargers for Ski-Doo snowmobiles now feature welded turbine inlets, which reduce weight and backpressure while improving flow to the turbo.

Air Box

Durably Built

Robust design allows for best air flow from the turbo. Stainless Steel construction, finished with bake-on ceramic coating.

Tuned Backwall

Designed to correctly reflect acoustic waves from the E-TEC intake, maintaining stock engine system efficiencies that are critical to the E-TECs performance.

Turbo Optimized

Correctly shaped to provide optimal air volume to the Aerocharged E-TEC engine.

Snow to Air Intercooler

Harness The Cold

The most effective intercooler ever made for a snowmobile. This performance upgrade is an intercooled airbox that rapidly cools the air charge from the turbo by directing water, snow and ice from the tunnel through the intercooler core. This intercooled airbox installs into the Ski-Doo tunnel, requiring moderate modification to the tunnel. Testing shows that this intercooler provides a more consistent heat-sink than traditional Air-Air ICs, and is significantly more engine-friendly than Air-to-Water setups. The air charge is being cooled as soon as the track is moving, without putting any additional load on the engine, coolant and electrical systems.

Competition-Grade Equipment

Aerocharger developed this intercooler to give our riders a competitive edge on race day. It proved to be extremely effective, and has now been made an option at the consumer level.

Stainless Steel Exhaust

Flow-Through Design

This muffler has been sized to flow exhaust from the turbo quickly and effectively.

TIG Welded

Optimized Exit Angle

The front facing departure avoids blockage by trailing the snowmobile’s A-Arms. This placement was tested by top backcountry riders, who found this to be the most effective setup.

Clutching

Best Performance

An extensive clutch setup is included in all 2013-14 packages, specifically configured for best operation on Aerocharged Ski-Doo snowmobiles.

Full Setup

Includes a dual-angle helix that can be set for racing performance or backcountry conditions. Also comes with custom ramps, adjustable tungsten weights, primary spring, an alternate top gear, chain and oil, and Aerocharger’s recommended settings based on boost and altitude.

Fuel Management

Exclusive Fuel Programming

The Aerocommander fuel controller is pre-mapped with a proprietary program to fully optimize the Aerocharger’s performance with the E-TEC. Maps are updated annually for improved performance. The Aerocommander is fully plug-and-play right out of the box.

Sequential Injection

External MAP Sensor

New for 2013, the fuel controller hardware now includes an external three-bar manifold absolute pressure sensor. An external sensor provides an improved reading for smooth fueling, and makes the Aerocommander unit 100% water proof. Comes with a 2 Year Warranty.

Also Included

Custom Charge Tube

Silicone Construction – lightweight and durable for high pressurization.

Guage Panel

Innovate AFR Guage and Custom Boost Guages are included.

Stinger Kit

Parts and instructions are included to modify the stock pipe with an Aerocharger stinger. This pipe is larger in diameter and improves exhaust flow for better performance. Will require cutting and welding the stock pipe.

Turbo Reeds

Upgraded turbo reeds are provided with every Aerocharger E-TEC system. Developed by BRP based on use with Aerocharged E-TECs, these reeds are more robust and have a longer life during turbocharged use.

Heat Shield

Ceramic Coated stainless steel for best thermal control.

Dome Filter

Stainless steel mesh intake screen filter.

Vent Kit

Heat dissipation is critical for best turbo performance. 7 Snow Silk vents are included, with templates and instructions for easy installation. An Advanced Snow Silk Ski-Doo vent package is available in the Upgrade section.

Upgrades

RACE TEAM UPGRADES

Aerocharger offers several E-TEC performance upgrades. These options were developed for our race team, and are frequently requested by advanced tuners and riders.

Harness The Cold

Upgrades a non-intercooled 600/800 E-TEC system with an Aerocharger Air-to-Snow Intercooler. This performance upgrade rapidly cools the air charge from the turbo by directing water, snow and ice from the tunnel through the intercooler. This intercooler installs into the E-TEC tunnel, requiring moderate modification to the tunnel. Testing has established that this intercooler provides a more consistent heat-sink than traditional Air-Air ICs, and is significantly more engine-friendly than Air-to-Water setups. The air charge is being cooled as soon as the track is moving, without putting any additional load on the engine, coolant and electrical systems. This product is available in the Aerocharger Store.

Performance Backcountry Intake

This innovative Hybrid Snorkel Intake for Aerocharged E-TECs improves system efficiency in extremely deep conditions. By allowing for multiple intake areas, this design improves on traditional snorkel setups by increasing air flow and reducing the risk of blockage.Click Here for more info. This product is available in the Aerocharger Store.

Snow Silks Snowmobile Vent Kits

Heat Dissipation

Reducing engine compartment heat is extremely important for best snowmobile performance, and these Snow Silk vents provide superior air flow compared to other leading brands. Snow Silk vents are resistant to tears, feature durable adhesive, and have water-repellant properties to keep the sled interior clean and dry. CAD modeled for perfect fitment to the Ski-Doo XP/XM compartment panels. Includes cutting templates for easy installation.

The Basic Kit covers all major sled panels. The Deluxe kit adds vents for every remaining panel on the sled.

Mountain Performance Clutching

An extensive turbo snowmobile clutch kit for mountain use on Ski-Doo 800 E-TECs. This setup is included in all new systems. Includes a dual-angle helix that can be set for racing performance or backcountry conditions. Also comes with custom ramps, adjustable tungsten weights, primary spring, an alternate top gear, chain and oil, and Aerocharger’s recommended settings based on boost and altitude. This product is available in the Aerocharger Store.

XP to XM Upgrade Package – $199.00

Model Upgrade

This package contains all components required to adapt an Aerocharger XP kit for use on a Ski-Doo XM. Includes updated boost gauge, XM DES switch and gauge brackets, basic vent kit, left and right side panel supports, headlight support bracket, and all necessary rivets and hardware.

Testimonials

Runs great and so easy to ride that my 9 year rides it. Only running 5psi of boost. The power is real smooth coming on and you can go on and off the throttle pulling hills with trees with no worries.dooxtreme. Ski-DooSnoWest

Setup was a piece of cake and I don’t have to fiddle with it all the time.mctrailboss. Ski-DooSnoWest Online

You can be in and out of the throttle as much as you want, as often as you want…but then squeeze it when you need it, and all the power’s there…in spades.longgold. Polaris ProRMKSnoWest Online

All I can say is… phenonmenal – best sled I’ve ever ridden, by far. The installation is top-notch – very clean, the sled is ran flawlessly.Jeff Todd. Ski-Doo E-TEC 800

I got your turbo kit yesterday and have just started up the sled. I just have to say; this kit is the best kit I’ve ever mounted. And I have built several (competitor) nytros and (competitor) pro turbos. This kit is completely on another level. The fit and finish is WAY better. Thanks. Kim Rune Frantzen. Ski-DooNorway

Power is really smooth and linear just like the stock setup, just alot more there to be had. tuning with the aero box has been a breeze, last weekend we were out at gorman and were riding between 3000ft and 9000ft and didnt even touch the thing.oler1234. Ski-DooSnowAndMud.com

My riding buddy ran an Aerocharger on his 13xm… He was basically pull and go all season. I don’t think he ever messed with anything other than going to a wider belt to get lower engagement. I would recommend based on his experience.polarisfornow. Ski-DooSnoWest

Aero has been working with Ski-Doo and producing kits for the E-TEC for, I believe, 4 years now. I cant speak too the other builders quality, ease of installation, rideability, etc. but tough not to take a hard look at the Aero kit. Aerocharger knows their stuff when it comes to the Ski-Doo!nuttyn01. Ski-DooSnowest

I have ridden 2 different Aerocharger kits and have been impressed with the ease of use and reliability.Sledhead455. Ski-DooSnoWest Online

Snow To Air Intercooler works great. Power is really nice and linear just like stock, except a lot more. Anyone who is thinking turbo, go get one. You will really question why you wasted a season thinking about it and waiting.oler1234. Ski-DooSnowAndMud

We use only the best products with our kits and you will find there is no cleaner or easier installation. The only turbo we’ll use is the AerochargerTurbo Performance

Aerocharger Turbo: That bad boy will drag any carcass out of the woods.sir boost a lot. Ski-DooSnowAndMud.com

“This is the greatest turbo kit ever!… Installs easy and cosmetically pleasing to the eye! Worked so good, I got myself into some pretty hairy spots!”Aalren LentmanLacombe - Alberta, Canada

I love my Aerocharger kit. It’s running great and the guys at Aerocharger have been there every time to help with my questions.mctrailboss. Ski-DooSnoWest Online

I have about 700kms on my sled now with the Aero kit. I installed it myself and it was very easy to do. Setup as per Aerocharger recomendations. I haven’t messed with fuel settings at all and it has never missed a beat.mctrailboss. Ski-DooSnowAndMud.com

“This turbo makes great power and has zero turbo lag, it really simplified my installation in my snowmobile. The turbo is great and the tech support I got was great too.”Dustin Young

“Installed the Aerocharger onto my stock M8 and turned this sled from stock into amazing. Really turned some heads and climbed some hills!!!! Awesome!”Jarret RossEckville, Alberta

I have had Aero on two different sleds ran at safe boost levels up to10 psi on my sled at my riding elevation. They were pull and go all season.ACTM7. Arctic CatSnoWest Online

When you get into the thick of the trees, you’ve turned down and stopped facing downhill, but want to go up…the power is there in an instant. I did NOT notice lag…and im very acutely tuned to noticing lag.longgold. Polaris ProRMKSnoWest Online

I have an Aero and think it’s the funnest fun that can be bought.kfa670. Ski-DooSnoWest Online

I got Aerocharger’s wire dome filter, and it is incredibly well built. Far superior to some concoction I would have created.rotaxhippie. Ski-DooSnoWest Online

I am very happy with the performance. Because I did the install myself, I had a few questions for the guys at Aerocharger and they were great every time. Hands down the funnest sled I’ve ever ridden.mctrailboss. Ski-DooSnowAndMud.com

With all the turbo kits on the market, I’m glad I went with Aerocharger Turbos. It is user friendly and very reliable.Kyle Pratt. Ski-Doo

You don’t want to not have this kit, it works so well. You will only regret it later.109rmsha. Ski-DooSnoWest Online

I was pulling 7900 on clicker2, and 1150 EGT’s at 12000 ft – blew away everything on the hill.Jeff Todd. Ski-Doo E-TEC 800